This document discusses hazards, risks, and safety in industrial processes. It defines hazards as anything with the potential to cause harm, and risk as the probability of a hazard resulting in an accident. It emphasizes the need to identify hazards, analyze what could go wrong and its consequences, and defeat the accident process through inherent safety, hazard identification, and risk assessment. Key safety statistics discussed are OSHA incidence rate, fatal accident rate, and fatality rate.
This document discusses hazards, risks, and safety in industrial processes. It defines hazards as anything with the potential to cause harm, and risk as the probability of a hazard resulting in an accident. It emphasizes the need to identify hazards, analyze what could go wrong and its consequences, and defeat the accident process through inherent safety, hazard identification, and risk assessment. Key safety statistics discussed are OSHA incidence rate, fatal accident rate, and fatality rate.
This document discusses hazards, risks, and safety in industrial processes. It defines hazards as anything with the potential to cause harm, and risk as the probability of a hazard resulting in an accident. It emphasizes the need to identify hazards, analyze what could go wrong and its consequences, and defeat the accident process through inherent safety, hazard identification, and risk assessment. Key safety statistics discussed are OSHA incidence rate, fatal accident rate, and fatality rate.
This document discusses hazards, risks, and safety in industrial processes. It defines hazards as anything with the potential to cause harm, and risk as the probability of a hazard resulting in an accident. It emphasizes the need to identify hazards, analyze what could go wrong and its consequences, and defeat the accident process through inherent safety, hazard identification, and risk assessment. Key safety statistics discussed are OSHA incidence rate, fatal accident rate, and fatality rate.
Introduction Prof. Shishir Sinha Department of Chemical Engineering.
1 Safety, Hazards & Risk Safety or Loss Prevention is the prevention of accidents by the use of appropriate technology to identify the hazards of a chemical plant and to eliminate them before an accident occurs. A hazards is anything with the potential for producing an accident. Risk is the probability of a hazards resulting in an accident. Hazards • An inherent physical or chemical characteristic that has the potential for causing harm to people, the environment, or property. • Hazards are intrinsic to a material, or its conditions of use. • Examples Hydrogen sulfide: toxic by inhalation. Moving machinery: kinetic energy pinch points. Gasoline: flammable. For any Industrial Process Plant, Following questions must be asked and answered • What are the Hazards ? • What can go wrong and how? • What are the chances? • What are the consequences? ANALYSIS Experienced personnel brainstorming a series of questions that begin, "What if…?” Each question represents a potential failure in the facility or misoperation of the facility. The response of the process and/or operators is evaluated to determine if a potential hazard can occur. Question Areas Equipment failures What if … a valve leaks? Human error What if … operator fails to restart pump? External events What if … a very hard freeze persists? ANALYSIS
What if the Raw Material contains impurities?
What if Cooling Water is Lost? What if the Vessel Agitation Stops? What if Power Supply Fails? What if the Temp./ Press. Sensor Fail? What if the Pump Stops? etc. Steps
1. Divide the system up into smaller, logical subsystems
2. Identify a list of questions for a subsystem 3. Select a question 4. Identify hazards, consequences, severity, likelihood, and recommendations 5. Repeat Step 2 through 4 until complete HAZOP Hazard and Operability Analysis
• Identify hazards (safety, health,
environmental), and
• Problems which prevent efficient
operation
9/49 SAFETY PROGRAMS
Safety regulation requires five ingredients
• Safety knowledge • Safety experience • Technical competence • Safety management support • Commitment Scope (elements of process safety management) 1. Accountability 2. Process Knowledge and Documentation 3. Capital Project Review and Design Procedures 4. Process Risk Management 5. Management of Change 6. Process and Equipment Integrity 7. Human Factors 8. Training and Performance 9. Incident Investigation 10. Company Standards, Codes and Regulations 11. Audits and Corrective Actions 12. Enhancement of Process Safety Knowledge Features and characteristics of a management system for process safety Planning Organizing Well-defined goals and objectives Strong sponsorship Well-defined scope Clear lines of authority Clear-cut desired outputs Explicit assignments of roles and Consideration of alternative achievement responsibilities mechanisms Formal procedures Well-defined inputs and resource Internal coordination and communication requirements Identification of needed tools and training Implementing Controlling Detailed work plans Performance standards and Specific milestones for measurement methods accomplishments Checks and balances Initiating mechanisms Performance measurement and reporting Internal reviews Variance procedures Audit mechanisms Corrective action mechanisms Procedure renewal and reauthorization • SAFETY PROGRAMS They thought they were safe • “Good” companies can be lulled into a false sense of security by their performance in personal safety and health • They may not realise how vulnerable they are to a major accident until it happens • Subsequent investigations typically show that there were multiple causes, and many of BP Deepwater Horizon these were known long before the event Why and how defence fail • People often assume systems work as intended, despite warning signs • Examples of good performance are cited as representing the whole, while poor ones are overlooked or soon forgotten • Analysis of failure modes and effects should include human and organizational aspects as well as equipment, physical and IT systems Process safety management • Recognition of seriousness of consequences and mechanisms of causation lead to focus on the process rather than the individual worker
• Many of the key decisions influencing safety
may be beyond the control of the worker or even the site – they may be made by people at another site, country or organization
• Causes differ from those for personnel
safety
• Need to look at the whole – materials,
equipment and systems – and consider individuals and procedures as part of the system
• Management system approach for control
SAFETY ASPECTS • The most effective means of implementing a safety aspect is to make it everyone's responsibility in a process plant. • The older concept of identifying a few employees to be responsible for safety is inadequate by today's standards. • All employees have the responsibility to be knowledgeable about safety and to practice safety. • It is important to recognize the distinction between a good and an outstanding safety process. SAFETY ASPECTS • A good safety process identifies and eliminates existing safety hazards.
• An outstanding safety process has management
systems which prevent the existence of safety hazards. Process Safety
associated with a process, and this reduction or elimination is permanent and inseparable from the process. Example: use a less toxic raw material to produce a product. Inherently Safer Process Methods
Minimize: Reduce quantity in process.
Substitute: Use less hazardous raw materials. Moderate: Use lower temperatures and pressures. Simplify:Reduce unnecessary complexity in the design and operation.
- What can go wrong & how ? probabilit consequence y s - What are the chances ? - Consequences ? Risk determination
EXTREMES: risk &
hazard N - Low probability Modify design acceptable - Minimal consequences ? Y Accept system Hazard Identification Why? To identify hazards so that they can be eliminated or controlled. How? Using a number of available procedures. THE ACCIDENT PROCESS Most accidents follow a three-step sequence.. Initiation: the event that starts the accident.
Propagation: the event or events that
maintain or expand the accident.
Termination: the event or events that stop
the accident or diminish it in size. THE ACCIDENT PROCESS • It is unrealistic to expect elimination of all initiations.
• A much more effective approach is to work on all
three areas to in sure that accidents, once initiated, do not propagate and will terminate as quickly as possible. DEFEATING THE ACCIDENT PROCESS DEFEATING THE ACCIDENT PROCESS Accidents & Loss Statistics These are the important measures of the effectiveness of safety process. These statistical data must be used carefully. Mostly they represent only average and do not reflect the potential for single episodes involving substantial losses. Accidents & Loss Statistics
The major systems are-
1. OSHA incidence rate 2. Fatal accident rate (FAR) 3. Fatality rate or deaths per person per year Accidents & Loss Statistics OSHA incidence rate (OIR)- The term incidence rates means the number of injuries and illnesses, or lost workdays, per 100 full-time workers. Else based on cases per 100 worker years. A worker year = 2000 hrs 50 work week per year & 40 hrs/ week. The OSHA incidence rate (OIR) is based on 200,000 hrs of worker exposure to a hazards Accidents & Loss Statistics OIR is calculated from the number of occupational injuries, illness and the total number of employee hours worked during the applicable period. Occupational injuries- Any injury such as a cut, fracture, sprains etc. which results from a work accident or from an exposure involving a single incident in the work environment. Accidents & Loss Statistics Occupational illness- An employee is any abnormal condition or disorder, other than one resulting from an occupational injury caused by exposure to environmental factors associated with employment. It includes acute and chronic illnesses or diseases which may be caused by inhalation, absorption or direct contact. Accidents & Loss Statistics Lost workdays are those days which the employee would have worked but could not because of occupational injury or illness. The number of lost workdays should not include the day of injury or illness . Accidents & Loss Statistics Lost workdays (Contd..) The number of days includes all days (consecutive or not) on which because of injury or illness. The employee would have worked but could not. The employee was assigned to a temporary job. The employee worked at permanently assigned job but could not perform all duties normally connected to it. Accidents & Loss Statistics Recordable cases- are those involving an occupational injury or occupational illness, including death. Not recordable cases- are first aid cases which involve one time treatment. Accidents & Loss Statistics Nonfatal cases without lost workdays are cases of occupational injury or illness which did not involve fatalities or lost workdays but did result in, Transfer to another job or termination of employment. Medical treatment other than first aid. Diagnosis of occupational illness. Restriction of work or motion. Accidents & Loss Statistics OSHA incidence rate: based on injuries & illness OIR = (No. of injuries & illness × 200,000) / (Total hours worked by all employees during period covered) An incidence rate can also be based on lost workdays. OIR (based on lost workdays) = ( No. of lost work days × 200,000) / ( Total hours worked by all employee during period covered) Accidents & Loss Statistics Fatal Accident Rate (FAR)- The FAR reports the number of fatalities based on 1000 employees working their entire lifetime. The employees are assumed to work a total 50 years. The FAR is based on 108 working hours
FAR = ( No. of fatalities × 108) / ( Total hours
worked by all employees covered ) Accidents & Loss Statistics Fatality rate or deaths per person per year:
Fatality rate = (No. of fatalities per year) /(Total no. of people in
applicable population) This approach is useful for performing calculation on the general population where the number of exposed hours is poorly defined. Accidents & Loss Statistics Property damage and loss of production must Incident Pyramid: also be considered in 1 Serious/Disabling/Fatalities loss prevention. These Medical Aid Case 10 losses can be Property Loss/1st Aid Treatment substantial. 30
Accidents of this type 600 Near Misses
are much more common 10,000
Unsafe Behaviors/Conditions
than fatalities. Accidents & Loss Statistics The exact numbers vary by industry, location and time. It is frequently said, "the cause of an accident is visible the day before it occurs“. Inspections, safety reviews, and careful evaluation of near misses will identify hazardous conditions which can be corrected before real accidents occur. S-A-F-E-T-Y
S- Management Systems A- Proper Attitude F- Understand Fundamentals E- Experience T- Time to do things safely Y- Your Participation Thank You
